Apparatus for monitoring a package handling system

ABSTRACT

A monitoring apparatus for sensing conditions associated with a package handling system. The monitoring apparatus includes a test package configured for being handled by the package handling system with non-test packages handled by the package handling system. The test package has a housing defining a test package interior and has at least one sensor positioned within the interior for sensing conditions associated with the package handling system. The sensor produces an output signal corresponding to the conditions that it senses. The test package further includes a support positioned within the test package interior and connecting the sensor to the housing so that the sensor is directed generally toward an outside of the test package for sensing conditions associated with the package handling system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.12/169,230, filed Jul. 8, 2008 now U.S. Pat. No. 7,982,764, which isincorporated herein by reference, together with any and all attachmentsand exhibits thereto. The full benefit and priority of all applicationsare claimed.

FIELD OF THE INVENTION

Various embodiments of the present invention relate to a monitoringapparatus and, more specifically, to apparatus for monitoring conditionsassociated with a package handling system.

BACKGROUND OF THE DISCLOSURE

Package handling systems, such as conveyor belt systems moving packagesor parcels about a warehouse or delivery hub, sometimes experienceoperational problems, such as a jam of the packages being handled by thesystem or a break in a conveyor belt of the system. Operators of thesesystems sometimes monitor conditions associated with the systems fordetermining when problems have occurred. Conventionally, if suchmonitoring is performed at all, it is often performed by personnelwalking around the system looking for unwanted events or conditions.

Monitoring a package handling system using people walking around thesystem can be expensive, especially when it is determined that multiplepersonnel are needed to effectively monitor the entire system at onetime. Monitoring a package handling system using people constantlyinspecting the system can also be expensive considering the time periodsat which monitoring is desired. For example, considering that somepackage handling systems may run continuously, monitoring personnelcould be needed for most of the hours of a day and even perhaps for24-hour monitoring. Moreover, personnel often cannot see certain aspectsof the package handling system during operation of the system, such aswithin tunnels or other equipment of the package handling systemsthrough which packages move while being handled.

BRIEF SUMMARY OF THE DISCLOSURE

Various embodiments of the present invention relate to an apparatus formonitoring conditions associated with a package handling system. Themonitoring apparatus includes a test package configured for beinghandled by the package handling system with non-test packages handled bythe package handling system. The test package has a housing defining atest package interior. The test package also has at least one sensorpositioned within the interior of the housing for sensing conditionsassociated with the package handling system. The sensor produces anoutput signal corresponding to the conditions that it senses. The testpackage further includes a support positioned within the test packageinterior and connecting the sensor to the housing so that the sensor isdirected generally toward an outside of the test package for sensingconditions associated with the package handling system.

Various embodiments of the present invention relate to a method ofmonitoring a package handling system using a test package, wherein thetest package has an interior and a sensor positioned therein. The methodincludes sensing conditions associated with the package handling systemusing the sensor of the test package while the test package is beinghandled by the handling system.

BRIEF DESCRIPTION OF THE DRAWINGS

Having described various embodiments of the invention in general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 is a perspective of a monitoring system according to a particularembodiment of the present invention shown in combination with a packagehandling system.

FIG. 2 is a perspective of a test package of the monitoring system shownin FIG. 1.

DETAILED DESCRIPTION OF THE DISCLOSURE

The present invention will now be described more fully hereinafter withreference to the accompanying figures, in which some, but not allembodiments of the invention are shown. Indeed, this invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein. Rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout.

Various embodiments of the present invention are directed to anapparatus for monitoring a package handling system. The monitoringapparatus of these embodiments includes a test package having at leastone sensor for sensing conditions associated with the package handlingsystem, such as a leak or a tear in a part of the handling system. Inparticular embodiments of the present invention, the sensor includes avideo camera for capturing images of the package handling system. Inparticular embodiments, the test package includes a wireless transmitterand the package handling test system also includes remote devices havinga receiver and a processor for receiving and processing wireless signalsreceived from the test package sensor to determine whether an unwantedcondition of the package handling system (e.g., a leak or a tear) ispresent. The remote devices may also include communication elements,such as a visual display or siren, connected to the processor. Thecommunications devices may be used for, among other purposes, notifyingusers of the package handling system when an unwanted condition exists.

Referring to the figures, and more particularly to FIG. 1, a monitoringapparatus according to a first embodiment of the present invention isdesignated in its entirety by reference number 10. The monitoringapparatus 10, or test package system, includes a test parcel or package12 and may include remote devices 14 with which the test package canwirelessly communicate. The monitoring apparatus 10 is used formonitoring conditions associated with a package handling system 16, suchas a conventional conveyor belt system used for transporting packageswithin a warehouse. During operation of the monitoring apparatus 10, thetest package 12 is positioned within the package handling system 16 formonitoring the system while it is being handled by the system.

The package handling system 16 may include machinery, devices, vehicles,and people and is not limited to a conveyor system. For example, in someembodiments, the package handling system 16 may include a subsystem inwhich the test package 12 is picked from an inventory shelf, a conveyingsubsystem (e.g., as shown in part in FIG. 1), and post-conveyingsubsystems, such as people and machines moving the test package to adelivery truck, which may also be part of the package handling system.The monitoring apparatus 10 may be used in combination withnon-monitoring or non-test packages 18 being handled within the packagehandling system 16 with the test package 12. The test package 12 mayresemble the non-test packages 18 in many ways, such as in size, shape,and material.

The test package 12 includes one or more sensors 20 for sensingconditions associated with the package handling system 16. The sensors20 may include various types of sensing devices, such as video camerasand infrared sensors. For embodiments of the present invention in whichthe sensors 20 include cameras, the cameras may be high-definition andlow-light-capable cameras. Whatever their type, the sensors 20 mayinclude self-leveling and shock-absorbing features available in manymodern sensors. Other exemplary types of sensors 20 that may be used aspart of the test package 12 include ultrasonic sensors, chemicalsensors, photo detectors, radar detectors, thermal sensors, capacitancesensors, speed sensors, accelerometers, and sensors for detecting amagnetic field. Each sensor 20 produces a sensor output signalcorresponding to the conditions that it senses.

The test package 12 may also include a transmitter 22 operativelyconnected to the sensors 20. The transmitter 22 is arranged to receivethe sensor output signals and wirelessly transmit the signals to theremote devices 14. The transmitter 22 may be a transponder, being ableto transmit communication signals (e.g., sensor output signals) and alsoreceive communication signals. It is contemplated that in someembodiments the transmitter 22 may be configured for receiving signalsfrom the sensors 20 and/or from outside of the test package 12 andtransmitting the signals to a local processor positioned within the testpackage, but not for transmitting data signals out of the test package.

The transmitter 22 may be connected to the sensors 20 in a variety ofways such as by way of wires or by wireless connection usingcorresponding wireless devices (e.g., Wi-Fi or Bluetooth®) positionedwithin or connected to the transmitter 22 and the sensors 20 (Bluetoothis a registered trademark of Bluetooth Sig, Inc., Corporation, ofBellevue, Wash.). The remote devices 14 may be positioned remote fromthe test package 12 being handled by the package handling system 16. Forexample, the remote devices 14 may be positioned at a central locationwithin a warehouse in which the package handling system operates or evenmore remotely, such as remote from such a warehouse. It is contemplatedthat the monitoring apparatus 10 may also be connected to a network,such as the Internet, for users of the apparatus to monitor or evaluateconditions associated with the package system at various times and fromvarious locations.

The remote devices 14 of the monitoring apparatus 10 may include areceiver 24 and a processor 26 connected to the receiver. The receiver24 is arranged for receiving wireless signals from the transmitter 22 ofthe test package 12 and transmitting the signals to the processor 26.The receiver 24 may be a transponder, being able to receivecommunication signals and also transmit communication signals, such asreceiving communication signals from the transmitter 22 in the testpackage 12 and sending signals to the transmitter. It is contemplatedthat in some embodiments the receiver 24 may be configured for receivingsignals from the remote processor 26 and transmitting them to the testpackage 12, but not for receiving signals from the test package.

As described below in further detail, the remote processor 26 may beconfigured to process the signals received from the sensors 20 by way ofthe transmitter 22 and the receiver 24. The processor 26 may beconfigured to process the sensor output signals by, for example,analyzing the signals to determine in real time whether an unwantedcondition of the package handling system 16 exists at any particulartime as the test package 12 is moving through the system. Exemplaryunwanted conditions are a rip or tear in a conveyor belt of the packagehandling system 16, a leak in the handling system, a jam of packagesbeing handling in the system, and characteristics indicating alikelihood of the presence or an imminent presence of such conditions.The unwanted conditions associated with the package handling system 16can also relate to characteristics of the non-test packages 18, such astears or leaks of the non-test packages. The test package 12 may alsomonitor desired or normal operations associated with the packagehandling system 16, such as normal movement of a conveyor belt of thepackage handling system 16, such as a speed of the conveyor belt whenthe speed is within a desired range.

The remote processor 26 may consider present or real-time data andhistoric data received from the test package 12 related to the packagehandling system 16. However, it is contemplated that the processor 26may consider data received from sources other than the test package inmonitoring the package handling system 16. For example, the processor 26may receive and consider data from a system identifying a location ofthe test package, such as system including the electronic reader (e.g.,RFID reader) reading the electronic indicia 46 (e.g., RFID tag). Asanother example, the processor 26 may consider data received from thepackage handling system 16, which may provide information to theprocessor, such as a speed of a conveyor belt in a particular section ofthe package handling system.

The remote devices 14 of the monitoring apparatus 10 may also includecommunication elements 28 operatively connected to the processor 26 fornotifying users of the monitoring apparatus of conditions of the packagehandling system 16. Further, it is contemplated that in some embodimentsof the present invention the communication elements 28 may be configuredto allow users of the apparatus 10 to input desired information, such asfor programming or instructing the processor 26 or the test package 12.It is also contemplated that, in some embodiments of the presentinvention, the communication elements 28 may be configured to allowusers of the apparatus 10 to selectively review information, such as forexamining present or real-time data and historical data produced by theprocessor 26 using the output signals of the sensors 20.

As shown in FIG. 2, the test package 12 includes a frame or housing 30defining an interior 32 of the test package. The sensors 20 and thetransmitting device 22 may also be positioned in the interior 32 of thetest package 12. The test package housing 30 may include one or moresurfaces 34, such as sides or walls. The sensors 20 may be connectedtogether by a sensor support 36, which may connect the sensors 20 to thehousing 30. For example, the support 36 may directly contact the sensors20 and directly contact the housing 30, although FIG. 2 does not show anembodiment in which the sensor support directly contacts the housing. Insome embodiments of the present invention (not shown in detail), thesensor support 36 includes one or more components connecting the sensors20 directly to the test package housing 30. For example, each sensor 20may be connected to the housing 30 by various components of the sensorsupport 36.

FIG. 2 generally shows a embodiment of the present invention in whichthe sensors 20, the support 36 connecting the sensors, and the housing30 are sized and shaped so that the sensors and support fit snuglywithin the housing so that a direct connection between the support andthe housing is not needed to secure the sensors in place in the interior32 of the test package 12. Instead, the sensors 20 directly contact thehousing 30, which contributes to holding the sensors 20 in place in thetest package 12. One or more parts of the housing 30, such as a wall, orpanel of a wall, of the housing may be movable as described more below,to allow access to the interior of the housing, such as for installingand removing the sensors.

The sensor support 36 may include any of a variety of materials. In mostembodiments of the present invention, the sensor support 36 ispreferably light-weight and sturdy. Exemplary materials for the sensorsupport 36 include plastic and aluminum. For absorbing shock that thetest package 20 may experience, such as during handling in the packagehandling system 16, it is contemplated that any one or a combination ofthe sensor support 36, the sensors 20, and the test package housing 30may include impact, shock, or vibration-absorbing features (not shown indetail). For example, the sensor support 36 may include a spring orother damper to absorb forces or shock experienced by the test package12, and thereby limit damage to the test package. The sensors 20 mayinclude conventional shock-absorbing features. As shown in FIG. 2, thesensor support 36 may also connect the sensors to the transmitter 22within the interior of the test package 12 and wires (not shown), whichmay connect the sensors and transmitter, may be disposed within thesupport. The test package 12 may also include a transmitter support (notshown) for connecting the transmitter 22 directly to the housing 30.

In some contemplated embodiments of the present invention, the sensorsupport 36 is configured to allow movement of the sensors 20 withrespect to other parts of the test package 12. For example, the sensorsupport 36 may include a gyroscopic arrangement whereby orientation ofone or more sensors 20 may be changed with respect to other parts of thetest package 12. In a particular such contemplated embodiment, thesensor support 36 is arranged so that a sensor 20 is generally keptdirected or biased in a specific direction, such as generally up orgenerally down. This bias can be accomplished using a support 36allowing movement of the sensor 20 with respect to other parts of thepackage 12, such as a gyroscopic-type support, and selectively locatedweights biasing the support toward a position in which the sensor isoriented as desired.

The test package housing 30 may have various sizes and shapes andinclude a variety of materials without departing from the scope of thepresent invention. For example, the test package housing 30 may beconfigured so that the test package 12 in many ways resembles non-testpackages 18 being handled by the package handling system 16.Particularly, for instance, the test package housing 30 may be sized andshaped like shells of some non-test packages 18 that the handling system16 usually handles. This resemblance can facilitate the test package 12being handled by the system 16 in a manner similar to the manner inwhich the non-test packages 18 are handled, thereby allowing the testpackage to generally move through the handling system with the otherpackages 18. The test package 12 can be configured to resemble non-testpackages 18 in many ways, including by being sized and shaped similar tomany non-test packages, having similar materials or similarly-behavingmaterials, and having similar weights.

Although the test package housing 30 may have other shapes withoutdeparting from the scope of the present invention, in one embodiment thetest package housing forms a six-sided generally rectangular or squarebox. In other embodiments, the package has other shapes, such as by aneight-sided box. Although the test package housing 30 may have otherlengths, widths, and heights without departing from the scope of thepresent invention, in one embodiment the housing has a length of betweenabout 6 inches and about 110 inches, a width of between about 6 inchesand about 90 inches, and a height of between about 6 inches and about 90inches. In one particular embodiment, the housing 30 has a length, awidth, and a height each being between about 10 inches and about 35inches.

Although the housing 30 of the test package 12 may comprise othermaterials without departing from the scope of the present invention, inone embodiment the housing includes a paper-based product, such ascardboard, paperboard, or corrugated fiberboard. In selecting materialfor the housing 30, a designer may seek a material having a relativelyhigh robustness so that the housing can generally maintain its physicalcharacteristics (e.g., shape) through substantial handlings in thesystem 16. Another variable that a designer may consider in selectingmaterial for the test package 12 housing 30 is an ability of the packageto impersonate the other packages 18 being handled by the system. Thatis, in some embodiments of the present invention, the test package 12 isconfigured so that the test package moving through the package handlingsystem 16 behaves similarly to non-test packages 18 moving through thehandling system 18, such as being carried by the system and respondingto stimuli from the system in similar ways.

The test package housing 30 may include a plastic, such as polyvinylchloride (PVC) or polymethyl methacrylate (PMMA), or another relativelyrobust material that would hold up through substantial handlings in thesystem 16. PMMA is also known as Plexiglas®, a registered trademarkowned by Arkema France, of Puteaux, France.

The surfaces 34 of the test package 12 may be configured to facilitateeffective sensing of conditions outside of the test package by thesensors 20. For example, for embodiments of the monitoring apparatus 10in which the sensors 20 include video cameras, the surfaces 34 caninclude visually transparent or translucent material positioned betweenthe cameras and outside of the test package 12 allowing the cameras tosee conditions outside of the test package. The test package housing 30may include more than one material or spaces being free of material. Forexample, the test package 12 may include mostly a relatively hard paperproduct or other generally opaque material (e.g. PVC) forming thehousing 30 at parts of the housing except at windows 35 positionedadjacent each sensor 20, between the sensor and outside of the testpackage. An exemplary window 35 is identified by dashed line in FIG. 2adjacent one of the sensors 20, but may be present adjacent any numberof the sensors 20.

The windows 35 of the test package 12 can be sized and shaped andcomprise material or lack material allowing the sensors to better sensethe conditions outside of the test package. For example, for embodimentsof the present invention in which the sensors 20 are video cameras, thewindows 35 can include a visually transparent or translucent material,such as Plexiglas®, allowing light to pass through the window and intothe cameras. For other types of sensors 20 (e.g., infrared orvibrational sensors), the windows may include other materials conduciveto facilitating effective operation of those sensors. In a contemplatedembodiment of the invention (not shown), one or more of the windows 35could be generally void of material, thereby being an opening adjacentthe respective sensors through which the sensors can effectively senseconditions outside of the test package 12. The sensors 20 may partiallyor completely fill such windows 35, such as is the case when a lens, ora rim of the lens, of a camera extends into the window.

The windows 35 of the housing 30 of the test package 12 may have variousshapes and sizes without departing form the scope of the presentinvention. For example, the window 35 may be sized and shaped to allowthe sensors 20 to sense conditions within a desired broad or desirednarrow range or scope. The shape of the windows 35 may be, for example,generally circular, oval, square, rectangle.

As mentioned above, the test package 12 may be configured to resemblenon-test packages 18 in many ways including by having a weight similarto a weight common to many non-test packages. Although the test package12 may have various weights without departing from the scope of thepresent invention, in one embodiment the test package weighs betweenabout 10 pounds and about 150 pounds. For example, in one particularembodiment, the test package 12 weighs between about 20 pounds and about50 pounds. In many embodiments of the present invention, the testpackage 12 is generally light, such as weighing less than about 40pounds, thereby making it easier for users to carry the test package,such as carrying the test package within the package handling system 16and to and from the handling system.

As shown in FIG. 2, the monitoring apparatus 10 may further include alocating device 38 for determining a location of the test package. Thelocating device 38 may be positioned within the test package 12. Thelocation of the test package 12 can be transmitted to, or determined in,the remote processor 26 of the monitoring apparatus 10. The remoteprocessor 26 can be configured to affiliate a location of the testpackage at a certain time, such as a present, real-time, location or ahistoric location, with conditions that the sensors 20 sense at thecorresponding time (i.e., real time or past time). As an exemplarylocating device 38, the monitoring apparatus 10 may include a globalpositioning system (GPS) receiver for receiving data from a GPSindicating or related to a position of the test package.

In one contemplated embodiment of the present invention (not shown), themonitoring system 10 includes multiple stationary signal stations (notshown) positioned adjacent and/or within the handling system 16 (e.g.,in a warehouse in which the handling system is positioned) for sendingand/or receiving locating signals (e.g., radiofrequency or RADARsignals) to/from a test package signal station in the test package 12.In this embodiment, the position of the test package 12 can bedetermined by, for example, evaluating distances between the signalstation in the test package 12 and the various stationary signalstations using a common method such as triangulation. Such evaluationcan take place in the test-package signal station or in a remote device,such as the remote processor 26, in a variety of ways. For example,location of the test package 12 can be determined at regular intervals(e.g., every 30 seconds) or upon occurrence of a particular happeningsuch as the user requesting the processor 26 to seek the location orautomatically upon determination that the sensors 20 of the test package12 have sensed a particular events, such as a problem or potentialproblem.

In a contemplated embodiment of the present invention, the locatingevaluation takes place in a local processor positioned within the testpackage 12 and connected to the locating device 38. Such a localprocessor is described below in further detail. The monitoring apparatus10 may be configured to determine the location of the test package 12 atany time. Knowing where the test package 12 is in real time as it sensesa problem or potential problem before it occurs can be useful for manyreasons, such as for accurately and quickly dispatching maintenancepersonnel.

As also shown in FIG. 2, the test package 12 may include a local powersource 40, such as a conventional battery. The local power source 40 canbe connected to any of the electronic parts of the testing package 12(e.g., sensors 20, transmitter 22, locating device 38), such as by wirespositioned within the sensor support 36, for providing operating powerto those parts. The local power source 40 can include a conventionalrechargeable battery. The local power source 40 can store power until itis needed by other parts of the test package 12. The local power sourcemay be a so called “super capacitor”, being rechargeable hundreds orthousands of times.

Exemplary local power sources 40 include nickel-metal hydride (NiMH)batteries, nickel-cadmium (NiCad) batteries, and lithium-ion (Li-ion)batteries. For embodiments of the present invention in which the testpackage 12 includes a rechargeable power source 40, the test package mayinclude a power interface (not shown in detail) connected to the localpower source by which the local power source can be connected to anexternal power source, such as a conventional wall socket, forrecharging the local power source. It is contemplated that such powerinterface may include a connection point positioned completely withinthe interior 32 of the test package 12. For allowing access to theconnection point of the power interface, the body 30 of the test packagemay be selectively movable, as described above. For example, one of thesurfaces 34, or a portion of one of the surfaces (e.g., a panel), mayinclude a hinge and a fastener for allowing a user to selectively accessthe connection point for charging the local power source 40 andthereafter securely close test package 12.

In other contemplated embodiments of the present invention (not shown indetail), the connection point of the power interface may extend to anexterior of the test package 12 so that a user may access the connectionpoint for charging the local power source 40 without moving one of thesurfaces 34 of the test package body 30 or a portion of one of thesurfaces. In such embodiments, the test package 12 may include a coverthat can be selectively positioned over the connection point of thepower interface of the local power source 40 for protecting theconnection point from external elements, such as moisture, parts of thepackage handling system 16, and non-test packages 18. The connectionpoint cover may include, for example, a flap that is hinged and closableby, for example, a clasp or other fastener or a spring mechanism forbiasing the cover to a closed position.

As mentioned above, the test package 12 may include a local processor42. The local processor 42 may be connected to the sensors 20, thetransmitter 22, the locating device 38, and the local power source 40.The local processor 42 may include any one of a variety of types ofprocessors, such as a programmable logic controller (PLC). The localprocessor 42 may be configured to process data received from variousparts of the test package 12, such as from the sensors 20 and thelocating device 38. As mentioned above, the transmitter 22 and thereceiver 24 may be transponders thereby allowing communication in bothdirections between the test package 12 and the remote devices 14.Accordingly, the local processor 42 may also be configured to receivedata from the remote processor 26 or other device (e.g., from thepackage handling system 16) by way of the transmitter 22 and processthat data.

In some contemplated embodiments of the present invention, the localprocessor 42 is configured to store data received from the sensors 20,instead of sending the data in real time to the remote devices 14, oralong with such real-time transmission. In these embodiments, datarelating to conditions of the package delivery system 16 sensed by thesensors 20 can be retrieved from the local processor 42 wirelessly or bywire connection (e.g., by wires positioned within the sensor support 36)at select times, such as after the test package 12 has completed anentire trip through the system.

The local processor 42 may also provide data to various parts of thetest package 12, such as by sending instructions to the sensors 20, thetransmitter 22, or the locating device 38, for controlling theiroperation. Specifically, for example, the local processor 42 may performan initial processing of the sensor output signals and provide theresult of the processing to the transmitter 22 for transmitting to theremote processor 26 for further processing. The local processor 42 mayalso communicate with the remote processor 26 by sending and receivingsignals to/from the remote processor by way of the local transmitter 22and the remote receiver 24. It is also contemplated that either or bothprocessors 26, 42 may communicate with a processor (not shown) of thepackage handling system 16 for reasons including controlling the packagehandling system 16, controlling the monitoring apparatus 10, andmonitoring the package handling, such as by evaluating data sensed bythe test package 12.

The local processor 42 may send various types of data to the remoteprocessor 26 and package handling system 16 in addition to datacorresponding to output signals of the sensors 20, such as test packagelocation data derived using data from the locating device 28. Throughcommunications with the package handling system 16, the remote and localprocessors 26, 42 can determine helpful data, such as a speed at whichthe conveyor belt is moving in a particular section of a conveyor beltsystem, despite the test package 12 indicating that the test package isnot moving in that section based on that sensed by the test package(e.g., there is a package jam in the system 16 keeping the test packagefrom moving). Moreover, the remote and local processors 26, 42 and thepackage handling system 16 may be connected together and configured suchthat the monitoring apparatus 10 can control all or part of the packagehandling system. This type of control may be useful for a variety ofreasons including for safety or maintenance reasons when the testpackage 12 senses a problem or a potential problem and changing theoperation of the system 16 or a section thereof, such as by temporarilyturning the system/section thereof off.

As shown in FIG. 2, the test package 12 may include an identifier 44such as a label. The identifier 44 may be the same as, or in many waysresemble identifiers positioned on non-test packages 18 usually handledby the system 16. The identifier 44 may include any of multiple types ofidentifying indicia, such as electronic indicia 46, a bar code 48, andhuman-readable indicia 50, such as a printed address or identificationnumber. As an exemplary electronic indicia 46, the test package 12 mayinclude a radiofrequency identification tag (RFID tag), which can beconfigured to store data. For the present application, the RFID tag canbe arranged to store data relating to an address or identificationnumber for the package, such as the address or identification numbershown in the human-readable indicia 50. Data stored on the RFID tag canbe read by an RFID reader (not shown in detail), which may be a part ofthe monitoring apparatus 10, or a part of the package handling system16. For example, RFID readers may be strategically positioned atlocations within the package handling system 16 for determining when thetest package 12 and non-test packages 18 pass particular points in thesystem. The RFID readers may also be used to identify along which routeof multiple routes of the package handling system 16 the test package 12and non-test packages should be guided by the system.

The identifier 44 can be changed or replaced with another identifierduring use or between uses of the test package 12. For example, theelectronic indicia 46 may be reprogrammed for associating differentidentifying information with the test package 12. As another example,the test package housing 30 and the identifier 44 may be configured sothat the identifier can be easily removed, such as by pulling on an edgeof the identifier thereby overcoming a force (e.g., adhesive, magnetic)holding the identifier to the housing, and replaced by anotheridentifier. As yet another example, the identifier 44 may be coveredwith a subsequent identifier so that the subsequent identifier may beread to identify the test package 12. In this way, the informationassociated with the test package 12, such as information determiningalong which route of the package handling system 16 the test packagewill be guided, can be easily changed for monitoring various aspects(e.g., sections) of the package handling system.

In some embodiments, the electronic indicia 46 (e.g., RFID tag) must bepowered in order to be read, while in others it does not need to bepowered to be read. Electronic indicia 46 needing to be powered in orderto be read may be powered in various ways. For example, in someparticular embodiments, the electronic indicia 46 may be connected tothe local power source 40, such as by wires. It is contemplated that thetest package 12 including the local power source 40 and the electronicindicia 46 may be configured so that the electronic indicia can receivepower wirelessly from the local power source. In other particularembodiments, the electronic indicia 46 can be powered by wirelesssignals, such as radiofrequency signals being transmitter to theelectronic indicia. It is contemplated that the test package 12including the electronic indicia 46 may be configured so that theelectronic indicia receives power from the local power source 40 andfrom incoming wireless signals during operation of the test package 12.

As described above, the monitoring apparatus 10 may include remotedevices 14 including the receiver 24, the processor 26, andcommunication elements 28 connected to the processor for communicatinginformation to users of the apparatus and receiving information from theusers. The transmitter 22 of the test package 12 and the receiver of theremote devices 14 of the monitoring apparatus 10 may be configured in avariety of ways, allowing various types of communications between thetransmitter and the receiver. For example, the transmitter 22 and thereceiver 24 can each be configured for communicating using Wi-Fi,radiofrequency (RF), infrared, Bluetooth®, wireless local area network(WLAN), or other types of signals (Bluetooth is a registered trademarkof Bluetooth Sig, Inc., Corporation, of Bellevue, Wash.).

The remote processor 26 may include various types of computing devices.For example, the processor 26 may include a relatively simpleprogrammable logic controller (PLC), a central processing unit (CPU), ora more complicated server or network of more than one of these devices.The processor 26 may be configured, such as by being programmed, toprocess data received from the test package 12 in a variety of wayswithout departing from the scope of the present invention. For example,in one embodiment, the processor 26 is configured to receive image datafrom sensor cameras of the test package 12 and to store the image dataand/or communicate the image data to users of the monitoring apparatus10 by way of the communications devices 28.

The remote processor 26 may also analyze data received from the testpackage 12 for automatically identifying particular events correspondingto the sensed conditions associated with the package handling system.For example, the processor 26 may be programmed to recognize when outputsignals of the sensors 20 indicate a problem in the package handlingsystem 16. For instance, for embodiments of the present invention inwhich the sensors 20 are cameras, the processor 26 can be configuredwith an optical or image recognition algorithm or software package foranalyzing images received from the sensors for evaluating conditionsassociated with the package handling system 16 and identifyingparticular events therein.

Optical recognition software can be programmed to analyze a variety offeatures within image data, such as is the case with conventional humanface, retina, or fingerprint recognition software. The remote processor26 may be configured to recognize events such as temperatures associatedwith the package handling system 16 (e.g., a temperature of a conveyorbelt or a delivery vehicle cargo hold) being above or below a particularrange or threshold, presence of moisture within or adjacent the system,presence of a jam of packages in the system, or a broken part of thesystem, such as a torn conveyor belt. The remote processor 26 may alsobe configured to determine whether such an event is possible, probable,or imminent based on the sensor 20 output data. For example, when thetest package 12 senses that it and/or non-test packages 18 are beingslowed below a certain speed, or below a certain speed for a certainamount of time, not amounting to a conclusion that there is already ajam, the processor may recognize that the sensed conditions indicate apotential, impending, or likely future package jam.

The monitoring apparatus 10 can include a calibrating or learningfunction in which the test package is stimulated (e.g., by actualhandling in the system 16) and the processor 26 is programmed torecognize particular stimuli (e.g., a torn conveyor belt or a slow testpackage speed) as being associated with particular sensor output signalsreceived by the processor during the learning (i.e., a learning phase).It is contemplated that the apparatus 10 may learn by sensing,processing, and being programmed before and during use of the apparatus.The processor 26 may also be configured to combine various pieces ofreal-time data and/or historic data received from the sensors todetermine a present condition of the package handling system 16 orpredict likely or sure future conditions.

In some contemplated embodiments of the present invention, themonitoring apparatus 10 includes more than one test package 12, whichmay be introduced into the package handling system 16 at the same time.In these embodiments, the remote processor 26 may be configured toprocess real-time data and/or historic data received from the multipletest packages 12 in evaluating operation of the package handling system16.

The remote processor 26 may also be configured to determinecharacteristics associated with the test package 12 based on datareceived from the sensors 20. For example, the processor 26 may useoptical recognition software to determine a speed, orientation, orlocation of the test package 12 based on images of the surroundingenvirons of the test package as it is being handled by the packagehandling system 16. For instance, the processor 26 can be programmedduring the learning phase while the test package 12 is being movedthrough the package handling system 16 to recognize that various sensedstimuli (e.g., images received by camera sensors) correspond to variouslocations within the package handling system. Such test package 12location data created by the processor using sensor 22 output signalsmay be further processed by the remote processor 26 instead of locationdata from the locating device 38 that may be in the test package 12,from package-location information from other sources, or in combinationwith any of these sources of location data.

It is contemplated that the local processor 42 and the remote processor26 may be configured to include any or all of the features describedherein regarding the other. For example, the local processor 42 may beprogrammed to analyze image data received from the sensors 20 fordetermining whether the sensors are sensing an unwanted conditionassociated with the package handling system 16.

As shown in FIG. 1, the communication elements 28 may include a visualdisplay 52 for displaying information received from the processor 26.The processor 26 may be configured (e.g., programmed) to provideinformation to the visual display 52 for display to the user in any of avariety of formats, such as lists, spreadsheets, charts, and graphs.Information displayed by the visual display 52 can advise users ofconditions associated with the package handling system 16 (e.g., “Apackage jam is imminent on conveyor number two”. Such information mayalso include instructions advising the users how to proceed (e.g.,“Please evacuate area four”, “Please repair belt”, and “Please alleviatejam”).

The communication elements 28 of the monitoring apparatus 10 may alsoinclude an acoustic source 54, such as a speaker, buzzer, horn, orsiren. By way of the acoustic source 54, the processor 26 can audiblycommunicate messages to users of the monitoring apparatus 10 and thepackage handling system 16. These messages can be verbal, advising usersof conditions associated with the package handling system 16 (e.g., “Apackage jam is imminent on conveyor number two”. Such verbal message mayalso include instructions advising the users how to proceed (e.g.,“Please exit area four”, “Please repair belt”, and “Please alleviatejam”).

The communication elements 28 may include other types of visual sourcessuch as a light source 56. An exemplary light source is a light-emittingdiode (LED). As with the visual display 52 and the acoustic source 54,the light source 56 may receive signals from the processor 26 andoperate accordingly to communicate information to users of themonitoring apparatus 10 and the package handling system 16. For example,the light source 56 may include a green LED, a yellow LED, and a redLED, which may be selectively illuminated in response to correspondingsignals from the processor 26 to respectively indicate to users, forexample, good package handling system conditions, slightly orpotentially problematic conditions, problematic conditions, orinstructions for proceeding. The monitoring apparatus 10, and theprocessor 26 and light source 56 in particular, may also be configuredto communicate various messages to users in other ways, such as by beingilluminated/not illuminated or by blinking in various ways. Also, thelight source 56 may include a light behind a message, such as “Pleaseattend to jam on conveyor #2”, which may be illuminated by a light ofthe light source 56 at instruction of the processor 26.

The apparatus 10 may include multiple elements of the various types ofcommunication elements 28 (e.g., more than one visual display 52, morethan one acoustic source 54, etc.). The communication elements 28 may bepositioned at various locations, such as within the package handlingsystem 16, in a remote central monitoring office near the handlingsystem, and/or in an even further remote monitoring location, such asoff site from the handling system. Communication elements 28 positionedin particular locations may display information particular to thelocation. For example, a visual display 52 positioned within or adjacenta specific part of the package handling system 16 may displayinformation relevant only to users within or adjacent that part of thesystem (e.g., “Please attend to package jam in this area”) and anacoustic source 54 positioned within or adjacent a specific part of thesystem may provide instructions and/or tones audible in that area forcommunicating to users in or adjacent that area.

As also shown in FIG. 1, the communication elements 28 may also includevarious input elements, such as a computer keyboard 58 and a mouse 60.As described above, the processor 26 and communication elements 28(e.g., the keyboard 58 and the mouse 60) may be configured to allowusers of the apparatus 10 to provide desired information into themonitoring apparatus 10. For example, users may input information to theprocessor 26 by way of the keyboard 58 for programming the processor orproviding instructions or information to the test package 12 by way ofthe processor. For example, the user can communicate with the processor26 to program the processor to provide the user with only certaininformation, such as to display only information from a first sensor 20of multiple sensors of the test package 12. A user may also enable ortemporarily disable parts of the monitoring apparatus 10, such as byselectively turning sensors 20 in the test package 12 on or off. Forcommunications to and from the test package 12, the remote processor 26may interact directly with parts of the test package (e.g., the sensors20) or with the local processor 42, which in turn communicates with theother parts of the test package.

In operation, the test package 12 is placed in the package handlingsystem 16, such as by being placed on a conveyor belt of a conveyorsystem. Because the test package may be configured to resemble anon-test package 18 (e.g., in size, shape, material, labeling) that thesystem usually handles, the package handling system 16 can handle thetest package 12 during normal operation of the system. The test package12 may be introduced into the system 16 at a beginning of the system ordownstream of the beginning as desired.

As described above, in some embodiments of the present invention, morethan one test package 12 may be placed in the package handling system 16at the same time. These multiple test packages 16 may be introduced intothe system in various ways, such as by being introduced to the system atthe same place at about same time (e.g., sequentially), at differentplaces at about the same time, at the same place at different times, orat different places at different times. As mentioned above, the testpackage 12 may be handled by the package handling system 16 and monitorthe system at the same time that the system is handling non-testpackages 18.

While the test package 12 is being handled by the package handlingsystem 16, the one or more sensors 20 of the test package may senseconditions associated with the package handling system. For example,when one of the sensors 20 is a camera, the camera receives video orimages of the package handling system 16 and/or the environmentsurrounding the system. As another example, when one of the sensors 20include a thermal sensor, the thermal sensor measures thermalcharacteristics of the package handling system 16 and/or the surroundingenvironment.

After or while the sensors 20 are sensing conditions associated with thepackage handling system 16, output signals from the sensors aretransferred to the transmitter 22, which transmits the signal data tothe remote receiver 24 for transfer to the remote processor 26. Theremote processor 26 analyzes the signal data received from the testpackage 12 to determine whether the signal data indicates an interestingevent or condition (e.g., an undesired condition) associated with thepackage handling system 16, such as a package jam in the system or atear or leak from the system or from a non-test package 18 being handledby the system. The conditions sensed by the sensors 20 and identified bythe processor 26 can also include characteristics of the test package12, such as the speed, orientation, or location of the test package. Theprocessor 26 can also recognize when such characteristics are outside ofcertain specifications, such as when the package is moving faster than apre-determined speed.

As mentioned above, operation of the monitoring apparatus 10 may includea learning or calibrating phase in which the test package 12 issubjected to stimuli, such as by being moved through the packagehandling system 16, and the processor 26 is programmed to affiliateparticular stimuli with particular conditions or events. For example,the processor 26 can be programmed to recognize a tear in a conveyor bybeing taught what the conveyor belt looks like when intact and todetermine that a tear exists or may exist when the belt no longermatches its intact form. As another example, the processor 26 can beprogrammed to recognize a location of the test package 12 during thelearning phase by being programmed to affiliate particular imagesreceived from camera sensors 20 with particular parts of the packagehandling system 16. Users or designers of the monitoring apparatus canprogram the processor 26 using the communication devices 28, such as thevisual display 52 (e.g., computer monitor), the keyboard 58, and themouse 60.

Whether the processor 26 determines location of the test package 16 byway of processing sensor data 20 or by other means such as from data ofa locating device 38, knowing the location of the test package 12 can behelpful in many ways. For example, the remote processor 26, determiningthat a problem or potential problem associated with the package handlingsystem 16, can also recognize a location of the problem or potentialproblem. Knowing location of a problem or potential problem can beassist in monitoring the package handling system 10, such as by, forexample, allowing users of the package handling system 16 to quicklyattend to the problem or potential problem, allowing users of the systemto clear an area of personnel as a safety precaution, and allowing usersto selectively control the package handling system, such as by shuttingdown a section of the system.

In some contemplated embodiments (not shown in detail), the remoteprocessor 26 or the local processor 42 is connected to the packagehandling system 16. In these embodiments, the monitoring apparatus 10and the package handling system 16 may be configured so that themonitoring apparatus 10 may automatically control all or a part of thepackage handling system, such as by shutting down a portion of thesystem experiencing a problem or potential problem as determined by thetest package 12. The monitoring apparatus 10 may also be configured toprovide a notification or an alert at a central location, such as a roomin which the remote processor 26 sits, or in an area of the problem orpotential problem sensed by the test package 18, using the communicationelements 28.

As described above, the processor 26 may provide information to thecommunication elements 28 (e.g., the visual display 52, the acousticsource 54, the light source 56) for notifying users of conditionsassociated with the package handling system 16 in a variety of formats.For example, the processor 26 may present lists, spreadsheets, charts,or graphs to the user by way of the visual display 52. The processor 26may be configurable by users to provide these and other types ofinformation to the users based on signals received from the test package16. The processor 26 may also communicate messages to users in the formof verbal messages or sounds (e.g., tones) by way of the acoustic sourceor in the form of particular lights (e.g., lights having variouscolors), patterns of lighting (e.g., blinking), or illuminated signageincluding the light source 56.

Information communicated to the users via the communication devices 28can advise them of conditions associated with the package handlingsystem 16, such as a speed at which a conveyor is moving or a jam in thesystem. The information communicated to the users can also includeinstructions advising the users how to proceed, such as when theprocessor 26 causes the acoustic source 54 or monitors of the visualdisplay 52 to broadcast or display a message for all users to hear orsee or for users in a particular area of the package handling system(e.g., “Please attend to a package jam in this area”).

In these and other ways, the monitoring apparatus 10 according to thepresent invention can be used to identify particular conditionsassociated with the package handling system 16 and advise users of thoseconditions. By sensing particular conditions associated with the packagehandling system 16, the monitoring apparatus 10 can identify problemsand potential problems of the system. Early detection of problems andpotential problems can be especially helpful for maintenance andoperation of the package handling system 16 because it allows presentproblems to be addressed early, can limit negative effects (e.g.,personal injury or damage to packages 12, 18 or to the system 16), andallow targeted preventative maintenance.

When introducing elements of the present invention or the preferredembodiment(s) thereof, the articles “a”, “an”, “the”, and “said” areintended to mean that there are one or more of the elements. The terms“comprising”, “including”, and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements.

As various changes could be made in the above constructions withoutdeparting from the scope of the invention, it is intended that allmatter contained in the above description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

Many modifications and other embodiments of the inventions set forthherein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the inventions are not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended listing ofinventive concepts. Although specific terms are employed herein, theyare used in a generic and descriptive sense only and not for purposes oflimitation.

What is claimed is:
 1. A method of monitoring a package handling systemusing an apparatus including a test package having a sensor positionedwithin an interior of the test package, the method comprising: sensingconditions associated with the package handling system using the sensorof the test package while the test package is being handled by thehandling system.
 2. A method as set forth in claim 1 wherein the sensorincludes a camera and the sensing step includes capturing images of theconditions associated with the package handling system.
 3. A method asset forth in claim 1 wherein the test package further includes atransmitter connected to the sensor and the monitoring apparatus furtherincludes a processor remote from the test package and the method furthercomprises: producing a signal using the sensor, the signal correspondingto the conditions associated with the package handling system sensed bythe sensor during the sensing step; transferring the signal from thesensor to the transmitter; and transmitting the signal received from thesensor to the remote processor wirelessly using the transmitter.
 4. Amethod as set forth in claim 3 further comprising: processing the signalreceived from the transmitter of the test package using the remoteprocessor, the processing including analyzing the signal for identifyingwhether a particular event is occurring within or adjacent the packagehandling system.
 5. A method as set forth in claim 4 wherein theprocessor is configured so that the processing step includes analyzingthe signal to identify as the particular event at least one eventselected from a group of events consisting of an operational problem ofthe package handling system and a potential operation problem of thepackage handling system.
 6. A method as set forth in claim 4 wherein theprocessor is configured so that the processing step includes analyzingthe signal to identify as the particular event at least one eventselected from a group of events consisting of a jam in the handlingsystem, a leak in the handling system, a tear in a component of thehandling system, and a potential jam in the handling system.
 7. A methodas set forth in claim 3 wherein the monitoring apparatus furtherincludes a communication interface connected to the processor and themethod further comprises communicating with a user of the monitoringapparatus regarding the conditions of the package handling system usingthe processor and the communication interface.
 8. A method as set forthin claim 1 further comprising: introducing non-test packages into thepackage handling system; introducing the test package into the packagehandling system; and handling the test package and the non-test packagesat the same time using the package handling system; wherein the sensingstep is performed while the test package and the non-test packages arebeing handled using the handling system.
 9. A method as set forth inclaim 1 further comprising: affixing a first label to the test packagecorresponding to labels affixed to non-test packages; and readinginformation from the first label affixed to the test package while thetest package is being handled by the package handling system.
 10. Amethod as set forth in claim 9 wherein the first label includes at leastone label element selected from a group of label elements consisting ofa bar code, an RFID tag, and human-readable data.
 11. A method as setforth in claim 9 further comprising: removing the first label from thetest package and affixing a second label to the test package; andreading information from the second label affixed to the test packagewhile the test package is being handled by the package handling system.12. A method as set forth in claim 9 wherein the monitoring apparatusfurther includes a locating subsystem and the method further comprisinglocating the test package while the test package is being handled by thepackage handling system using the location subsystem.